Manufacture of coated sheet



MANUFACTURE OF COATED SHEET hee Maier/'al like Erpe/f* Hea P/osh'c Cre/Ding Adhesive.

62 70 Hem* Plasic Naerio/ 9j Lower Melfi/73 l 6.; Poi/1f Lm@ ,45p/10.111. mmm umm lr Crepec/ Liner? 67 Adhesive.

April 6, ,1937. A. L. SPAFFORD MANUFACTURE OF COATED SHEET 2 sheets-sheet 2 Original Filed Aug. 17, 1931 Patented Apr. 6, 1937 MANUFACTURE FL COATED SHEET Allen L. Spafford, Cloquet, Minn., assixnor, by mesne assignments, to The Paper Service Company, Cincinnati, Ohio, a corporation of Ohio Original application August 17, 1931',v Serial No. 557,564. Divided and this application April 5,

1933, Serial No. 664,506

12 Claims.

The present invention relates to a coated sheet, to the manufacture thereof, and to structures employing said sheet, andthe manufacture of said structures. It has special reference to a coated paper adapted particularly for adhesive use, such as a liner for insulation blankets, and also to one which may be water-proof in character. This application is a division of my copending application Serial No. 557,564, led August 17, 1931.

In the U. S. Rowe Patents No. 1,628,515 and No. 1,782,767 there are described several methods of creping heavy papers with a heat plastic material. In my recentU. S. Patent No. 1,774,573 there is described a method of simultaneously l5 making such creped papers and embodying them in insulation blankets, employing the coated creped paper as a liner, and employing the heat plastic material as an adhesive to `hold the liner to a mat of insulation material.

20 Certain disadvantages of the insulation product so made are inherent in the character of the liner. Because the liner is coated with heat plastic material only on the inner side, the outer side presents a fibrous surface, and is not water-proof.

25 The nature of the creping process makes it diicult to coat both sides of the paper with the heatplastic material. Where asphalt is ,employed as the heat plastic material, the single asphalt coating used in creping, renders the insulation blanket 30 referred to water-proof on one side, but the uncoated side may absorb water and be thus materially weakened when wet. It is of course possible to water-proof the fiber side of the creped paper, but because it is creped, the recesses therein re- 3'5 ceiv and retain abnormal amounts of proofing agent, wasteiully, forming an uneven coating, with an additional disadvantage that the flexibility and elasticity of the final product is lessened. It is 'also disadvantageous to use certain 40 types of water-proofing sizes or compositions on the fiber side of the paper because the same will stien the paper. This may seriously interfere with the hot creping operati-ons, and the proofing agents may not withstand the heat of the creping operations. The ber of the paper may be eiectively saturated with a water-proofing agent, such as an oil, wax, tar, or low-melting-point asphalt. Such impregnation is not as desirable as the pre- 50 ferred embodiment of this invention whereby the fibers are not impregnated per se. The preferred embodiment on paper has the felted bers in a dry felted state characteristic of paper, and has the two surfaces coated with the water-proofing 55 agents. Thus the strength of the sheet is preserved, and can be maintained when the sheet is wet with water.

In accordance with the presentinvention I employ on the fiber side referred to a iiexibleV heat-resistant material such as a heat-plastic material like asphalt having a higher melting point than the heat-plastic material employed in the creping process, whereby said fiber side may be economically coated or water-proofed-with-l out interfering with the creping process. or the properties of the creped product.

The material which is applied as a proofing agent on the fiber side should preferably not be tacky or sticky at ordinary temperatures or in a higher range, say from 60 F. to 120 F. A tacky coat would make the sheet difficult to handle and would cause it to stick to itself when rolled, or. to rolls in machines, or to other things, according to the use of the paper. Such paper is desirably rolled for storage or shipment or in manufacture. It may be stacked in sheets, or used as wrappers on packages or articles, such as insulation blocks. In any such use adjacent layers should not stick. Of. course, a sticky or tacky coating might be used and be dusted with talc, mica, or other powder, or be protected by special sheets of material to which it would not stick. As above stated it ,I

is preferable to use a high-melting-point asphalt which is not tacky or sticky under the various conditions given.

Although I have above referred particularly to creping, the present invention is not limited to creped paper or to creping processes, but con- Y templates an-uncreped sheet having a heat-resistant flexible coating on one side and a heatplastic material on the other side, or having heat plastic coatings on the two sides, which have separated melting points, so that the whole may be heated to melt or soften the lower-melting coat,- ing for adhesive purposes, without causing injury to the other substance, such as causing the higher melting substance to become adhesive. A further contemplation of the present invention is the use of a flexible water-proofing agent on one side of a sheet, which agent is resistant to heat applied to soften a coating on the other side to render said coating adhesive. Itis particularly to be pointed out that the higher-melting point asphalt, which I prefer to employ may tend to` become adhesive un-der heat which may be used when the lower-melting point asphalt is applied, or. thereafter used in heating it to render it adhesive. In the event both coatings should become simultaneously adhesive when hot, on cooling the one becomes non-adhesive while the other remains adhesive. Also, I prefer to use the higher-melting asphalt in a much thinner coating, even impregnating to a slight degree only the surface of the sheet, and to use the adhesive and creping asphalt in a much thicker coating,

so that there is a residual quantity for adhesive use, as in uniting the sheet to insulation material. The thinner the coat or lm, the less is its ten- -dency to be adhesive. f Thus by means of the `present invention I provide a water-proofed sheet of material, such as paper, which may be creped, and which may be heated to cause one side to adhere to another surface. One object of the invention is the manufacture of a sheet with coating materials thereon which may be treated to render one coat useful as a adhesive or as a creping adhesive.

A particular object of the present invention is the manufacture of a sheet which is waterproof on one side, and which has on the other side a heat-plastic material of adhesive character when hot.

A particular object is the manufacture of a creped sheet of paper having the qualities -above referred to. Another object of the invention is the coating of a sheet of material with heat-plastic substance on both sides, the substance on one side having a lower melting point than the substance on the other side. Still another object is the manufacture of a sheet coated ori one side with material which becomes adhesive when hot, and coated on the `3 other side with any material which resiststhe plastic material of a sheet which is coated'on one` side with a water-proof heat-plastic substance having a higher melting point than the creping mate A still further object of the invention is the manufacture of an insulation blanket having an externally water-proofed plane or creped paper liner.

Various other objects and advantages of the invention will become apparent from the following description of the invention, and of the exemplary embodiments thereof which are shown in the accompanying drawings, in which:

, Fig. 1 represents in cross-section a sheet of doubly coated material suitable for creping or adhesive union to articles.

' Fig.' 2 represents in cross-section a sheet of doubly coatedmaterial suitable for creping with heat or applying to articles with heat.

Fig. 3 represents in cross-section a creped sheet of doubly coated creped material.

Fig. 4 represents apparatus and process diagrammatically illustrated for forming the sheets oi Figs. 1 and 2, the creped sheet of Fig. 3, and the structures of Figs. 5, 6, 7, and 8;

Fig. 5 represents across-section of an elastic flexible insulation blanket, taken on the line ,n 5-5 of Fig. 7.

Fig. 6 represents a cross-section oi! a rigid decorative panel or insulation structure, taken on line 0-6 of Fig. 8.

. Fig. 7 is a plan view of a section oi' a continuu ous length of insulation blanket Shelving the manner of forming a sealed edge with the creped liners.

Fig. 8 represents in small scale a plan view of a panel covered with ay creped sheet.

In carrying out the invention sheet material, such as heavy paper. cloth, cellulose, or other material in woven, felted, or hn form, is coated on one side with a water-prooilng agent which resists heat and which is flexible with the sheet. I prefer to use an asphalt, because it is cheap, but other materials may be used such 'as exible synthetic resins, as described in the U. S. Byck Patent No. 1,590,079, which .may be soluble in liquids in their physical forms before final' reaction, and insoluble after final reaction, or other synthetic resins, such as those described in the U. S. Davis Patent No. 1,649,058, which' may be soluble in Vilnally reacted form and which are modified. `,Highly plasticized nitrocellulose films may be employed.

On the other side of the sheet material I apply while plastic a heat-plastic substance which is normally solid, flexible in thin layers, non-adhesive and non-tacky. but which may become adhesive or tacky on the application o f heat.

Preferably I employ a substance which softens or melts to a viscous or a fluid state on application of heat, and which later cools to its normal state.

For the preferred usages of this invention I employvasphalt or`other bituminous substance of like character. This is an example of a nonreactive substance which can be repeatedly heated and cooled to bring about adhesiveness. Where coated paper is merely creped with a heat-plastic material, andis not to be subsequently employed for adhesive use, it may be crepedy with a. plastic material such as synthetic hereinafter referred to as the proong coat, is

capable of remaining effective, flexible and nonadhesive or non-tacky under heat which softens or is used with the second-mentioned coating, that is, the adhesive-coating or creping-coating.

For some purposes I prefer that the proofing coating soften materially at the temperature at which vthe adhesive coating is liquid, or viscous, and adhesive.

Under the conditions last mentioned the sheet material carrying the proofing coat will be suiilciently -exible so that the sheet may be readily hot-creped using the adhesive coating material as the hot-creping material.

By reason of the normal non-adhesive character of the two coats the coated sheet may be supplied in rolls, either creped or uncreped, forV trovasse terial is attractive, flexible, strong and tough, is a good substitute for canvas, bunting and the like, and may be used for out-of-door decorations. In such' use, it is so cheap, compared to 5 fabric, that it may be destroyed after a short period oi usefulness, as in building and street decoration.

In the drawings Fig. 1 shows a sheet, as of heavy paper I0, having a proofing coat Il, which l is primarily flexible either in thin layers, or when impregnated into the sheet and which is preferably heat resistant. There is an adhesive coat I2 which is preferably heat-plastic or plastic and adhesive when heat is applied. The materials l5 previously referred to may be used, but I prefer to use a high-melting-point asphalt as the proofing coat II and a'lower-melting-point asphalt as the adhesive coat. In Fig. l the flexible coat `II is not necessarily one which softens or melts', like asphalt. The resins referred to are examples of other materials which are primarily flexible. Where the adhesive coat is activated by heat, the .coat II is suitably resistant to the applied heat and also flexible at the applied heat. VWhere creping may be effected with a plastic adhesive, not necessarily heated, the coating II need not be heat resistant, so long as it is flexible for permitting creping.

In Fig. 2 a sheet I3 is shown, such as heavy paper coated with a heat-resistant material I4 which may melt, and which becomes soft and extremely flexible, although not adhesive, when an adhesive coat I5 is liquid, or soft and adhesive, as in applying to the sheet, as in creping the sheet, or as in applying the doubly coated sheet to a surface with the aid of heat. I prefer the proofing coat I4 to be a high melting point asphalt and the adhesive coat I5 to be a lower melting point asphalt.

I prefer asphalt to the viscous synthetic resins because the asphalt is viscous when hot, for both coats, and it may be applied to merely coat or partly to impregnate the paper, without complete y penetration or impregnation. A sheet coated with asphalt as shown in Fig. 2 may be torn and considerable material of the sheet, where it is a felted pulp sheet, may be readily seen as unimpregnated fibers.

` InV Fig. 3 a creped sheet is illustrated having a sheet base, such as kraft paper I6, coated with 'a proofing agent I1, which is heat-plastic and very flexible at a heat employed in creping, such as a high-melting-point asphalt. 'I'he other coat I8 may be any coat which is heat-plastic for use.

in the creping process. I may use a plastic or heat-plastic synthetic resin, or like-mixture capable of forming a synthetic resin, but I prefer to use a relatively chemically stable composition which is non-changeable with heat, within the limits of the process employed. Therefore, I prefer asphalt, and use the softening character of it with heat to form an adhesive coat.

The specific manner in which I carry out the invention for the manufacture of insulation blanket is illustrated in Fig. 4. The purpose is to feed a supply of the doubly-coated sheet, while hot and adhesive, to a mat of insulation, to secure the sheet to the mat as a liner therefore. I combine the heating and creping in one operation, and rather than supplying the proofed sheet from a roll, to the creping apparatus, I supply the sheet material itself and apply the two coats in the same machine which in character of operation is continuous.

A paper supply roll 2li feeds a sheet of kheavy paper 2I such as kraft paper over a heated drum 22 which rotates in a bath of high-melting-point asphalt 23, in vat 24. Idler rolls 26 are employed on each side o! the drum. A suitable melting point for the asphalt is 225 F. Great variation is permitted imthe melting point of asphalt, and it is to be understood that it is not sharply defined. At its so-called melting point it is viscous or sufficiently liquid to be called melted, for spreading purposes. It may be previously melted at a higher temperature, such as 380 F., at which lt is more liquid. I may incorporate a small quantity of wax, or paraffin i'nto this asphalt while it is so uid, to decrease the tackiness of the asphalt which may be exhibited at the heat used in creping. The addition of wax is not necessary and its addition may be omitted or controlled in accordance with the desired results and in accordance with the character of asphalt employed. It should also be understood that any asphalt having a so-called melting point of any particular degree or range, may be an admixture of a higher melting asphalt and a lower melting asphalt, and that any asphalt which is employed must be'selected or modified for the conditions which are to be employed in using the present invention.

The drum 22 maybe maintained at a temperature of 350 F. to `400 F. at which the asphalt is `sufficiently liquid to provide a thin coating.

After leaving the coating drum the coated sheet cools and the coating solidiiles to a non-adhesive and non-tacky condition. A considerable length of path for traveland cooling is provided, in

which idlers 26 may be used as is convenient or necessary for the apparatus. Where other materials are employed vthe travel after coating may be employed to cure the coating.` For example, if the sheet is proofed with a synthetic resin of the flexible variety, or material forming synthetic resins, the finishing steps may be started or completely carried out to effect a coating which will resist a heat application or roll-contact which may follow in a creping process.

The coated sheet then passes around, with the coated side against a heated roller or drum 21 which is a companion' roll forA the heated coating drum 28. 'Ihe latter drum revolves in a bathv 29 of low-melting-point asphalt in vat 30. 'I'he drums 21 and 2.8 may be heated to a temperature of 225 F. for applying an asphalt which melts between F. and 180 F., thus using ,the asphalt at a temperature at which it is suiliciently liquid to coat the paper. The doubly coated stretch of paper Adesignated 3l is sticky on the last coated side, and runs over a water-cooled roll 32, whereby both sides are chilled to a non-tacky state. The last-coated side then runs against and around roll 33 which is heated with warm water to a creping temperature, suilicient to render the adhesive coat sticky, and soft, and the proofing coat soft and plastic, but non-tacky. A rubber surfaced pressure roll 34 presses on the proofed side of the sheet. A knife or doctor blade 35 crepes and peels the creped sheet from the roll. Thereafter the speed of travel of the creped sheetnis reduced in proportion to the extent of creping. The creped stretch 36 is carried over a heated idler roll 3,1, and thence to means for disposing of the creped sheet. l

The sheet may be otherwise constituted so that it can be cooled and rolled where the sheet alone is desired. The creping plastic employed maybe varied to ybe non-adhesive under conditions where it is desired to so roll the sheet.

However, in the preferred use of a lower-melting asphalt it is utilized immediately while hot and st`lzy on the adhesive side. Traveling at the same speed as the creped sheet, there is shown a 5 traveling length of insulation or other material which is to be covered by the 'proofed paper. This may be a fiber board` which is rigid, fed in along length or in abutting or separated pieces of ilber board or other rigid or ilexible materials. In l0 the drawings I have illustrated a exible fibrous mat which may be of animal ber, such as hair, mineral fiber, such as asbestos or glass wool, or vegetable fiber, such as ax, eel grass, ground wood flber, or chemically pulped vegetable matter. I prefer to use wood fibers `adhesively united` in the manner described in the U. S. Weiss Patent No. 1,336,402, known as balsam wool.

Any such mat or other material, designated 88 is fed between two rolls 39 and 40, along with the creped liner 36. The roll 39 is heated to unite adhesively the mat 33 and the liner 36.

I prefer to use some other liner 4 I, preferably a similarly coated and creped liner, which passes over roll 40, likewise heated. The process and '25 apparatus employed for the liner 4I is substantially the same in its essential parts as previously described and are but briefly described. A paper supply roll 45 feeds paper aroundidlers 46, to pass it over a coatingdrum 41 running in high melting point asphalt 48. A scraper 48* is indicated to remove excess asphalt. The coated sheet is looped over idler 49 and carried to' idler 50 providing a cooling path. The cooled coated side passes over and against heated roll 5I presenting the ber side to coating drum 52 running in low melting point asphalt 53. 'I'he doubly coated sheet 54 runs over cooling roll y55, thence over the creping roll 56 and between it and the pressure roll 51, having associated doctor blade 58 and thence as creped liner 4i to heated roll 40. The final product which is obtained by the process speciilcally described is a water-proofed flexible, tough insulation blanket having elasticity in the direction across the crepe. It will be understood that other creping may be added to give elasticity in several directions or in any direction. The product is shown in detail in Fig. 5. The numeral represents insulation material such as adhesively united wood bers; 50 the numerals 6I and 62 represent the two creped paper liners; the numeral represents the zone of adhesive asphalt between a liner and the mat; and the numeral 64 represents the asphalt coating gn -the outside of the liner. Fig. 6 represents a product which may be made as above described, feedingal rigid section, such as ber board 65, to the creped sheet 66, carrying the creping adhesive Gl, such'as asphalt. The

sheet may be cheap ordinary kraft paper coated with a decorative or proofing coat 68, such as asphalt for water-proofness, or such as plasticized and pigmented nitro-cellulose which is exible, or a ilexible synthetic resin, which may be pigmented. Where a creping adhesive is used like 65 asphalt, .which becomes adhesive on applying heat, the paper .covering or other liner 66, whether creped or uncreped, may be supplied to the rigid board 55.

In making the panel of Figs. 6 and 8 theA creped sheet 66 and board 65 may have coincident edges. In making the insulation blanket one liner 62 may be wider, as shown at .10 in Fig. 7, and the mat Zand other liner 6I may have vcoincident; edges. The wider liner may have its edges folded over the edge and cemented to the narrow liner.

It may be sealedv with asphalt, which may be applied hot or which may be\.already on the paper and be suillciently adhesive to cement and seal the sheets. Thus a water-proofed sleeve is formed. Any length of the strip may be severed and the-cut edges be sealed by cementing a strip oi similar paper to the two liners, thus making a water-proof and water-resistant envelope.

It is also to be understood that although I have herein described one method of making the creped sheet directly from a sheet of uncoated paper, the invention maybe carried out by coating each side with the materials which are normally ilexible with the sheet. such as high-melting asphalt on one side, and low-melting asphalt, or other material which becomes adhesive when heated. vSuch a coated uncreped paper may be passed over a heating roll from a supply thereof to render one side adhesive for the purpose oi creping the same. More adhesive may'be applied at the same time, if desired, where its function is for adhesion rather than for creping.

Although I have described the use of heated asphalt for coating the sheet initially it is to b e understood that I do not limit the application' of asphalt to this method. Asphalt emulsions may be employed. Such emulsions commonly contain water. In the drawings the traveling coated paper is illustrated as undergoing curing, which may be drying water from an applied emulsion, cooling a hot coat of asphalt, or even the reacting of a synthetic resin where that is employed, or the drying of solvent from a cellulose base, such as nitrocellulose or cellulose acetate.

'I'he same asphalt or other material may be applied on two sides of a paper. One coat may be wet with a solvent or other liquid, so that the combined liquid and coating become a plastic and adhesive coating. Creping may be thus effected and a creped sheet may be adhesively united to another object. For example, high-melting asphalt may be coated -onto both sides of the sheet, and one side run over a roll, which, instead of being heated, is wet with a volatile solvent, such as benzol or naptha, for the asphalt, or a solution of asphalt. The liquid thus renders the coating plastic and effective to permit creping and/or adhesion. Solvent may thereafter be removed by evaporation.

Various other modifications of the invention may be made and it is to be understood that the invention is not to be considered as limited by the specific examples herein given as illustrative of the invention. In the appended claims I aim to denne the invention to include such changes and modifications as fall within the scope of the claims.

I claim:

l. The method of making creped sheets which comprises coating one side of ilexible sheet material with a heat-resistant coating which is exible with the sheet and non-adhesive at the below-mentioned creping heat, coating the other side of the sheet with a heat-plastic adhesive, passing the sheet over a heated roll with the adhesive side in contact with the roll to cause it to adhere thereto, and stripping the sheet from the roll whereby the sheet is creped.

2. 'I'he method of making creped sheets which comprises coating one side of exible sheet material with a high-melting bituminous substance which when normally cold is flexible with the sheet and non-adhesive at the below-mentioned creping heat, coating the other side with a lowermelting bituminous substance which is adhesive when the first-mentioned coating substance is non-adhesive, passing the sheet over a heated roll with the second coated side in contact with the roll to cause it to become adhesive to the roll, and stripping the sheet from the roll whereby the sheet is creped.

3. A coated sheet comprising a sheet of flexible material, a coating of high-melting bituminous substance on one side of said sheet, and a l coating of lower-melting bituminous substance on the other side of said sheet, the material of the two coats being so related in properties that at a given heat one is adhesive and the other is non-adhesive, but flexible, and such that each is normally non-adhesive and flexible with the sheet when normally cold.

4. A creped sheet comprising a sheet of flexible material, a coating on one side of the sheet which is normally flexible with the sheet and resistant 2O to the below-mentioned heat, and a coating on the other side of the sheet which is normally nonadhesive and flexible with the sheet and which is adhesive at an applied heat, said rst coating following the convolutions of the creped sheet and being creped therewith.

5. A creped sheet comprising a sheet of flexible material, a water-proof coating on one side of the sheet which is normally flexible with the sheet and resistant to the below-mentioned heat, and

a water-proof coating on the other side of the sheet which is normally flexible with the sheet and which is adhesive at an applied heat, said first coating followingthe convolutions of the creped sheet and being creped therewith.

6. A creped sheet comprising a sheet of flexible material, a coating of high-melting bituminous substance on one side of said sheet, and a coating of lower-melting bituminous substance on the other side of said sheet, the material of the two coats being so related in properties that both are normally flexible with the sheet and normally non-adhesive, and such that at a given heat the first-mentioned coat is non-adhesive and exible and the second coat is adhesive, said first coating following the convolutions of the creped sheet and being creped therewith.

7. A creped sheet of paper having unimpregnated felted fibers at the interior thereof, having a coating on one side thereof, and a coating of bituminous material on the other side thereof, the rst coating being non-adhesive at a heat at which the bituminous coating is adhesive, and said first coating following the convolutions of the creped sheet and being creped therewith.

8. A flexible creped sheet of paper having unimpregnated felted fibers at the interior thereof, having a high-melting bituminous substance on one side thereof, and having a lower melting bituminous coating on the other side thereof.

9. The method of making a coated sheet such as a liner which comprises coating one side of a flexible sheet material with a synthetic resin composition which is flexible with the sheet, coating the other side of the sheet with a substance which is normally non-adhesive and exible with the sheet and adhesive when hot, and creping the sheet with the action of heat on said adhesive material.

10. The method of making a coated sheet such as a liner which comprises coating one side of a flexible sheet material with a cellulose ester base composition which is flexible with the sheet, coating the other side of the sheet with a substance which is normally non-adhesive and flexible with the sheet and adhesive when hot, and creping the sheet with the action of heat on said adhesive material.

11. The method of making a coated sheet such as a liner which comprises coating one side of a flexible sheet material with a synthetic resin composition Which is flexible with the sheet, coating the other side of the sheet with an asphaitum adhesive, and creping the sheet with the action of heat on said asphaltum.

12. The method of making a coated sheet such as a liner which comprises coating one side of a flexible sheet material with a cellulose ester base composition which is flexible with the sheet, coating the other side of the sheet with an asphaitum adhesive, and creping the sheet with the action of heat on said asphaitum.

ALLEN L. SPAFFORD. 

